|Publication number||US5010140 A|
|Application number||US 07/363,272|
|Publication date||Apr 23, 1991|
|Filing date||May 31, 1989|
|Priority date||May 31, 1989|
|Also published as||EP0498914A1, EP0498914B1|
|Publication number||07363272, 363272, US 5010140 A, US 5010140A, US-A-5010140, US5010140 A, US5010140A|
|Inventors||Joseph A. Antonelli, Christopher Scopazzi, Mark M. Doherty|
|Original Assignee||E. I. Du Pont De Nemours And Company|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (7), Referenced by (50), Classifications (20), Legal Events (4)|
|External Links: USPTO, USPTO Assignment, Espacenet|
This invention relates to a process for preparing a stabilized polymer dispersion. It is more particularly directed to a process for preparing a dispersion of a polymer having an acrylic polymer core component and a polymeric stabilizer component, in which the stabilizer component is prepared using a cobalt catalytic chain transfer agent.
The stabilized polymeric dispersions prepared according to this invention are described in a general way in U.S. Pat. No. 4,746,714 to Spinelli, Scopazzi and Antonelli.
While those dispersions function very well for their intended purpose, the method described for their preparation provides no convenient way for incorporating living functional groups, especially hydroxyl groups, on the chains of the stabilizer polymer molecules. These functional groups confer certain advantages when the polymer system is to be cross-linked with melamines or isocyanates.
It has now been found that such groups can be easily incorporated on the stabilizer polymer molecules, in any number, if one uses a cobalt catalytic chain transfer agent in the polymer's preparation.
The principal polymers of the dispersions prepared according to the invention are described in U.S. Pat. No. 4,746,714, previously mentioned. That description, and the disclosures of how the polymers are prepared, are incorporated into this specification. The polymers described there have core components of acrylic polymers and substantially linear acrylic polymeric stabilizer components, each having a terminal polymerizable functional group, which are grafted to the core component at one end of the chain.
Illustrative of monomers which can be used to prepare the core components are those shown in the '714 patent, column 3, line 55, to column 4, line 25. Isocyanate, silane and amine functional monomers can also be used. Preferred for use in the process of the invention are methyl methacrylate, hydroxyethyl methacrylate, methacrylic acid, methyl acrylate, styrene and glycidyl methacrylate.
The monomers used to prepare the stabilizer component according to the invention can be any of the conventional polymerizable ethylenically unsaturated monomers. Preferred for use are butyl methacrylate, isobutyl methacrylate, 2-ethylhexyl methacrylate, hydroxyethyl methacrylate, methyl methacrylate, glycidyl methacrylate, itaconic acid or anhydride, maleic acid or anhydride, styrene, isocyanatoethyl methacrylate, benzene 1-(1-isocyanato-1-methyl ethyl)-3, 4(1-methyl ethenyl), methacrylic acid, acrylic acid, silanes and amines.
The ratio of monomer units in the final polymer is a matter of choice, as will be understood by those skilled in this art.
The catalytic chain transfer agent used in the process of the invention can be any compound which contains Co+2. Cobalt chelates are preferred, especially those described in U.S. Pat. No. 4,680,352 to Janowicz and Melby, and U.S. Pat. No. 4,722,984 to Janowicz. Most preferred are pentacyanocobaltate (II), diaquabis(borondifluorodimethylglyoximato)cobaltate (II) and diaquabis(borondifluorodiphenylglyoximato)cobaltate (II).
The chain transfer agents are ordinarily used at concentrations of 5-150 ppm based on monomers.
The process is run in two steps, the second of which can be run immediately after the first but which is ordinarily run after a pause for analysis and to permit more efficient use of the reactor.
In step one, a mixture of stabilizer monomers and organic liquid is heated, preferably to reflux temperature for ease of control, and to it is added the catalytic chain transfer agent of choice, additional monomer(s) and solvent, and the usual amount of a conventional polymerization initiator such as azo- or peroxide initiators. The reaction is run, with additions of monomers and initiator as needed, until the desired stabilizer component is obtained (ordinarily having a Mw of 5000-12000).
In step two, an organic liquid which is a solvent for the stabilizer component but a non-solvent for the core component is added to the product of step one. "Solvent" and "non-solvent" are being used in the conventional sense, as will be understood by those skilled in the polymer art. Illustrative of organic liquids which can be used are aromatic- and aliphatic hydrocarbons such as heptane and VM&P naphtha. Mixtures of liquids can also be used. The stabilizer/liquid ratio is of secondary importance, but is usually in the range 1/2 to 1/4 (weight).
The resulting mixture is again heated, preferably to reflux temperature for better control and to it are added the core monomers and a conventional initiator such as one of those previously mentioned, in the usual amount. Polymerization is continued, with additions of liquid and initiator as needed, until it is complete, as determined by periodic sampling and analysis.
The dispersions prepared according to the process of the invention can be used to modify the rheology and/or the physical properties of conventional coating compositions at concentrations of 1-80%, preferably 10-40%, by weight of the total composition.
Those skilled in the art will be able to practice this invention more easily after referring to the following illustrative examples.
Those artisans will no doubt be able to compose numerous variations on the themes disclosed, such as changing the amounts of ingredients slightly but insignificantly from those shown, adding innocuous substances, or substituting equivalent or nearly equivalent components for those shown. All such variations are considered to be within the inventive concept.
In the examples, all parts are by weight unless indicated otherwise.
To a reaction vessel were charged
______________________________________Toluene 827.2 partsn-butyl methacrylate 447.92-Ethylhexyl methacrylate 588.93-methacryloxypropyl- 108.1trimethoxysilane (A-174)______________________________________
This mixture was brought to reflux temperature, held there under nitrogen with stirring, and to it was then added, over a ten-minute period, a solution of
______________________________________1,1'-azobis(cyclohexane- 1.14 partscarbonitrile) (initiator)Diaquabis(borondifluoro- 0.023dimethylglyoximato)-cobaltate(II)n-butyl methacrylate 80.7Toluene 42.1______________________________________
The reaction mixture was then held at reflux temperature, with stirring, and to it was added, over a 60- minute period, a mixture of
______________________________________n-butyl methacrylate 209.02-ethylhexyl methacrylate 271.6A-174 (described above) 63.6Initiator 1.95______________________________________
This was followed immediately by the addition of a solution of
______________________________________n-butyl methacrylate 209.0 parts2-ethylhexyl methacrylate 304.9A-174 (described above) 63.0Initiator 2.12Toluene 84.4______________________________________
over a 180-minute period while maintaining reflux temperature. The reaction mixture was then held at reflux temperature, with stirring, for 30 minutes after which time was added, over a 60-minute period, a mixture of
______________________________________ Toluene 105.9 parts Initiator 0.5______________________________________
This reaction mixture was held at reflux temperature for 60 minutes, and toluene (246.3 parts) was then added to it and the mixture cooled. The resulting solution, 64.2% solids, contained the stabilizer component 2-EHMA/IBMA/A-174 50/40/10.
To a reaction vessel were charged
______________________________________Product of (A) 265.0 partsHeptane 396.0______________________________________
This mixture was brought to reflux temperature and to it were then added 0.6 parts of t-butyl peroctoate. The mixture was then held at reflux temperature and to it were immediately and simultaneously added, over a 210-minute period,
(1) A solution of
______________________________________Methyl methacrylate 207.9 partsMethyl acrylate 103.9Styrene 62.4A-174 41.6Heptane 19.3Product of A 128.8and______________________________________
(2) A solution of
______________________________________Heptane 67.7t-butyl peroctoate 6.2______________________________________
The resulting mixture was held at reflux temperature for 45 minutes, and to it was then added, over a 30-minute period, at reflux, a solution of
______________________________________Heptane 24.7 partst-butyl peroctoate 4.1______________________________________
This was again held at reflux temperature for 60 minutes, and 119.7 parts of solvent were boiled off to give a dispersion containing 55% solids.
The composition of the principal polymer in the resulting product was
To a reaction vessel were charged
______________________________________Toluene 853.5 partsIsobutyl methacrylate 495.22-ethylhexyl methacrylate 434.2Hydroxyethyl methacrylate 151.5______________________________________
The mixture was brought to reflux temperature (129° C.), held there under nitrogen when stirring, and to it was then added, over a 10-minute period, a solution of
______________________________________Diaquabis(borondifluoro- 0.033 partsdimethylglyoximato)-cobaltate II1,1'-azobis(cyclohexane- 1.0carbonitrile) (initiator)Hydroxyethyl methacrylate 36.6Toluene 38.0______________________________________
The reaction mixture was held at reflux temperature with stirring and to it was added, over a 240-minute period, a mixture of
______________________________________Isobutyl methacrylate 353.1 parts2-ethylhexyl methacrylate 414.0Hydroxyethyl methacrylate 213.8Toluene 76.3______________________________________
The reaction mixture was then held at reflux temperature with stirring for 30 minutes, after which time was added, over a 60-minute period, a mixture of
______________________________________ Toluene 227.9 parts Initiator 0.9______________________________________
The reaction mixture was further held at reflux temperature for 60 minutes and then cooled. The resulting solution, 63.6% solids, contained the stabilizer component 2-EHMA/IBMA/HEMA 40/40/20.
To a reaction vessel were charged
______________________________________Product of A 639.2 partsIsopropanol 44.0Petroleum naphtha 62.8Heptane 790.6Xylol 99.1______________________________________
The mixture was brought to reflux temperature (29° C.) and to it were added 1.6 parts of t-butyl peroctoate. The reaction mixture was held at reflux temperature and to it were immediately and simultaneously added, over a 210- minute period,
(1) a solution of
______________________________________Methacrylic acid 42.2 partsHydroxyethyl- 264.7acrylateMethyl methacrylate 370.3Methyl acrylate 190.6Styrene 158.9Glycidyl methacrylate 32.2Xylol 49.1Product of A 320.9and______________________________________
(2) a solution of
______________________________________Petroleum naphtha 157.0 partsButanol 27.9t-butyl peroctoate 15.9______________________________________
The reaction mixture was then held at reflux temperature for 45 minutes and to it was then added, over a 30-minute period, at reflux, a solution of
______________________________________Butanol 62.8 partst-butyl peroctoate 10.4______________________________________
The reaction mixture was held at reflux temperature for a further 60 minutes, at which time 304.8 parts of solvent were boiled off, to give a dispersion containing 55% solids.
The composition of the principal polymer in the resulting product was ##STR1##
The pentacyanocobaltates (II) and diaquabis(borondifluorodiphenylglyoximato)cobaltate (II) can replace the diaquabis(borondifluorodimethylglyoximato)cobaltate (II) catalytic chain transfer agent in the foregoing procedures, in equivalent amounts, with substantially the same result.
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|U.S. Classification||525/269, 525/286, 525/308, 525/268, 525/293, 525/288, 525/309, 525/301, 525/285|
|International Classification||C08F265/06, C08F2/08, C08F290/04, C08F2/14, C08F2/38|
|Cooperative Classification||C08F290/046, C08F265/06, C08F2/08|
|European Classification||C08F290/04C, C08F265/06, C08F2/08|
|Jul 14, 1989||AS||Assignment|
Owner name: E. I. DU PONT DE NEMOURS AND COMPANY, A CORP. OF D
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNORS:ANTONELLI, JOSEPH A.;SCOPAZZI, CHRISTOPHER;REEL/FRAME:005130/0160
Effective date: 19890515
Owner name: E.I. DU PONT DE NEMOURS AND COMPANY, A CORP. OF DE
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:DOHERTY, MARK M.;REEL/FRAME:005130/0288
Effective date: 19890516
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